Audi TT (2007 year). Manual - part 35

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not 
 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability 
     with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Valve stem seal fitting tool -3365-

♦ Removal and installation device for valve cotters -VAS 5161-

with knurled spacer ring -VAS 5161/23-1- and guide plate -

VAS 5161/23-

♦ Engine and gearbox support -VAS 6095-

♦ Cylinder head tensioning device -VAS 6419-
Procedure
– Remove camshafts 

⇒ page 121

 .

– Mark original positions of roller rocker fingers and hydraulic

compensation elements for reinstallation.

– Remove roller rocker fingers together with hydraulic compen‐

sation elements and put down on a clean surface.

– Insert cylinder head tensioning device -VAS 6419- into engine

and gearbox support -VAS 6095- .

– Secure cylinder head in cylinder head tensioning device, as

shown in illustration.

– Connect cylinder head tensioning device to compressed air.

3. Valve gear    

131

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not 
 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability 
     with respect to the correctness of information in this document. Copyright by AUDI AG.

– Using lever -arrow-, slide air pad under combustion chamber

where valve stem oil seal is to be removed.

– Apply just enough compressed air to bring air pad into contact

with valve heads.

– Fit guide plate -VAS 5161/23- onto cylinder head.
– Secure guide plate on intake manifold side with knurled screw

-VAS 5161/12- and at stud by screwing on 2 M6 nuts without

shoulder by hand until they make contact.

– Insert drift -VAS 5161/3- into guide plate and use plastic-head‐

ed hammer to release sticking valve cotters.

– Screw snap-in device -VAS 5161/6- with engaging fork -

VAS 5161/5- into guide plate.

– Slide knurled spacer ring -VAS 5161/23-1- onto assembly car‐

tridge -VAS 5161/8- .

– Attach pressure fork -VAS 5161/2- to snap-in device and push

assembly cartridge down.

– At the same time, turn knurled screw of assembly cartridge

clockwise until tips engage in valve cotters.

– Move knurled screw back and forth slightly; the valve cotters

are thus forced apart and taken up by the assembly cartridge.

– Release pressure fork.
– Take off assembly cartridge with knurled spacer ring.
– Detach valve spring with valve spring plate.

132

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not 
 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability 
     with respect to the correctness of information in this document. Copyright by AUDI AG.

– Pull off valve stem oil seal with valve stem seal puller -3364- .

Caution

Make sure valve stem oil seals are not damaged when instal‐

ling.

♦ New valve stem oil seals -B- are supplied with plastic

sleeve; fit plastic sleeve -A- onto valve stem.

– Lightly oil sealing lip of valve stem oil seal.
– Slide valve stem oil seal onto plastic sleeve.
– Carefully press valve stem oil seal onto valve guide using

valve stem seal fitting tool -3365- .

– Take off plastic sleeve.

If valve cotters have been removed from assembly cartridge, they

must first be inserted in insertion device -VAS 5161/18- .
• Larger diameter of valve cotters faces upwards.
– Insert valve spring and valve spring plate.
– Press assembly cartridge onto insertion device from above

and take up valve cotters.

– Insert assembly cartridge in guide plate -VAS 5161/23- again.
– Press down pressure fork and pull knurled screw upwards

while turning screw in both directions - this will insert the valve

cotters.

– Release the pressure fork with knurled screw still in pulled po‐

sition.

– Repeat procedure for each valve.
Assembling
Installation is carried out in the reverse order; note the following:
– Ensure that all roller rocker fingers make contact with the ends

of the valve stems correctly and are clipped onto their respec‐

tive hydraulic compensation elements.

– Install camshafts 

⇒ page 121

 .

3. Valve gear    

133

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not 
 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability 
     with respect to the correctness of information in this document. Copyright by AUDI AG.

3.9

Valve dimensions

Note

Inlet and exhaust valves must not be machined. Only grinding-in

is permitted.

Dimension

Inlet valve

Exhaust valve

∅ a

mm

28.10

26.00

∅ b

mm

5.975

5.965

c

mm

99.30

99.10

α

∠°

45

45

3.10

Machining valve seats

Note

Valve seats may not be machined due to the very small toleran‐

ces.

3.11

Checking valve guides

Special tools and workshop equipment required
♦ Universal dial gauge bracket -VW 387-

♦ Dial gauge -VAS 6079-

134